Explosion-proof battery



Feb' 8, 1944 H. E. JENSEN EXPLOSION-PROOF BATTERY 2` Sheets-Sheet l Filed Nov. 4, 1939 Feb. 8, 41944. H. E. JENSEN EXPLOSION-PROOF BATTERY Filed Nov. 4, 1939 2 Sheets-Shea?. 2

ZO z5 lw /ygmy if 2f; t J www5'- Patented Feb. 8, 1944 EXPLO SION-PROOF BATTERY Henry E. Jensen, Camden, N. J., assignor to Philco Corporation, a corporation of Pennsyl- Vania Application November 4. 1939, Serial No. 302,933

(Cl. 13B-179) l Claims.

This invention relates to storage batteries, and more particularly to storage batteries of the lead acid type, wherein the products of the chemical reactions during the charging or discharging of the battery cells include a mixture of gases which are potentially combustible or explosive. For example, common batteries of this type yield a mixture of hydrogen and oxygen,

, particularly toward the end of the charging cycle.

It is well known that these potentially explosive gases may be ignited by sparks or other static discharges which may occur, particularly during the iilling or testing of a cell, in spite of all reasonable precautions. In the case of large batteries especially, the chamber provided to permit the rise and fall of the electrolyte level may contain a sufficient quantity of mixed gases to crack or break the cell container if these gases are ignited. This destruction of the cell, and the consequent acid spray and spilling, not only involves costly damage, but also constitutes a serious hazard to the physical being of attendants or other persons.

Heretofore, various proposals have been directed toward prevention of explosions in batteries of this type.

According to the present invention, however, an adequate solution of the problem is attained, not by seeking to prevent entirely the explosion of gases, but by eiectively controlling the explosion in a manner to prevent any deleterious effects therefrom. This result is achieved by eifectively dividing the gas chamber above the electrodes and electrolyte into multitudinous irregular and interconnected gas pockets, cells or cavities which permit a series of small inconsequential explosions, but prevent the occurrence of any damaging or hazardous explosion.

The principal object of the invention, therefore, is to provide a novelbattery structure of this type.

A more speciiic object of the invention is to provide novel means for controlling any explosion in a battery of this type, such means comprising a mass of pervious material' forming small passages or gas pockets through which the liberated potentially explosiveA gasesmay flow. Other objects and features of the invention will appear hereinafter. l

In the accompanying drawings:

Fig. l is a horizontal plan view of a battery cell embodying the invention; v v

Fig. 2 is a part elevation and part sectional view of the cell, with the sectional part taken along line 2--2 of Fig. l; and

Fig. 3 is a similar view of a modification.

Referring iirst to Figs. 1 and 2, I represents the cell container which may be of hard rubber, glass or other suitable material. The plate elements and separators are indicated generally at 2 and may be immersed in a suitable electrolyte and supported by suitable mechanical kmeans notI shown. These plate elements may also be connected by suitable straps terminating in upwardly extending terminal posts 1 and 4. All of the above described construction may be of conventional design, according to present battery practice. 'Ihe battery is of the lead-acid type and the electrodes and electrolyte are of a character such that potentially explosive gases are liberated during electrolytic action of the battery.

The top or cover assembly of this cell is of novel construction, in accordance with the present invention, and may comprise two molded plate like sections of hard rubber 5 and i arranged in parallel, spaced relation to form a chamber therebetween. The lower section 5 is adapted to fit against the sides of the container and is perforated as shown at 1. The upper section 6 has a peripheral flange 8 which rests lupon and is secured to peripheral wall 9 o! section 5. The hollow cover assembly thus formed is provided with openings to receive the terminal posts, a filling tube I0, a vent tube Il, and a level indicator I2, as will be described in n greater detail later. Within the hollow cover structure is a pervious filling material I3 which divides the chamber into numerous small interconnected gas pockets, passages or spaces, thus preventing the occurrence of any potent explosion within the chamber, as will be described in further detail hereinafter.

The cover assembly above described may be sealed into the container in any suitable manner as by a sealing compound Il, the battery post openings also being properly sealed. The vent tube I I may be molded separately and fitted onto the cover section 6. This tube is preferably removable and should include a coarse molded grid I5. The filling tube I0 may be of any type properly secured in position, while the electrolyte level indicator I2 is of well known design.

While any suitable iiller material I2 may be employed, it is preferred to use loosely packed material such as stone, glass, crushed silica, or the like. This material should preferably be formed in small pieces of irregular configuration or shape. For example, glass crystals occupying approximately one-half of the normal volume of the chamber have been found satisfactory. Such s crystals may be formed easily and economically by pouring molten glass culotte into a Water tank,

thus forming large crystals, and then shattering these crystals by a suitable tumbling operation.

In one instance, glass crystals capable of passing.- through a half-inch screen, but incapable of passing through a three-eights inch screen were employed successfully in a chamber whose di- 2 l 2,341,382 l mensions were 16x 16x 5 inches and whose el any considerable amount of gas. Instead, the

ments were of hard rubber. While this size of gases within the small individual interconnected the pieces is considered preferable, it may be gas pockets burn in succession. Therefore, invaried at will by as much as one-fourth of an stead of the combustible gases generating an e/xinch if desired. If a glass container is used, the 5 plosion of considerable violence, a weak prolonged pieces should be slightly smaller, since glass is series of small explosions occur. In this case the less resistant to shock than hard rubber and the pressures created within the cell never reach such smaller pieces provide smaller interconnected gas strength as to cause damage to any of the elepockets, spaces or cavities. It is preferable that ments of the cell or the spraying of any acid the pieces of material should not have smooth or l0 therefrom, for the vent tube il serves as an uniform surfaces, but should be irregular and ample Outlet fOI the W pressure gases thus such as to break up the space between the plates generated- Further, the lOOse pieces of the ller 5 and 6 into numerous irregular, interconnected material will tend to absorb rather than transmit gas pockets, oeils or cavities, However, the inthe shock of the individual explosions.

vention contemplates the use of pieces of any It has been found by tests that When the gases suitable shape or size, In order to prevent the are ignited, an interval of several minutes must settling of the iier material |3 away from the elapse before the cell again contains suilicient poupper plete s, the under Side of this plate may tentially explosive gas to ignite. This feature be covered with e compound and e layer of finer insures that a continuous flame cannot be susmaterial may be secured to the cover by means tained by the gasesin the eeliof the compound l fl In addition to the foregoing major advantages, Since weight is 4sometimes an important factor, the Celi described above has been found t0 give the choice of iiller material may be governed acmaterially less acid spray than even the beSt of cordingly. `For example, sintered diatomaceous Conventional constructions, Particularly during earths may be used, and such material is characcharging- This feature is, ObVOusiY. highly deterized by iight Weight and high absorbency sirable in general, but is of primary importance In general, the iiller material should occupy when trl-e. batteries ajre used With exposed elecapproximately one-half the volume of the cham. trical wiring and switches, as in telephone subber and 4ll.' should provide interconnected gas station installations. 'I'he natural elimination of pockets, passages or spaces large enough subso sicld sprdy, by the cover assembly also results ln f -stantially to prevent capillary action (which an appreciable decrease in the electrolyte evap- Would' tendvfto close the spaces with electrolyte) brutlbrl rate' as Wlllbe readlly understood and yet small enough to prevent accumulation In. Fig. 3 there is illustrated the application of ln any one space or area of slllolont potentially this invention to a conventional or standard batexplosive gas to permit a potentlexplosion Ma-' 85 tery' cell or the lead'abld type' By means or the terials other thanfthose abovernentioned, such structure shown aud now to be descrlbed the tot as coarse glass Woblol. the like may b employed or cover of the conventional battery cell may be keeping inmind the above considerations and replaced by d tbpistructure constructed accord' governing the use ofthe material accordingly. lng t0 the Present invention and in this manner ,Inlthe operetionof the cell, the electrolyte is 4o the conventional betten' cell may be rendered maintainedebetwee the high and low levels, as substantially explbslbrl'proorindicated in Fig. 2. Since the cell herein shown Rererrlug t0 Flg- 31 there is Shown the con' and described is of the 1ead acld type, the elec ventional cell container I6 having the usual leadtrolyte is usually sulphuric'acid and the electrodes contalulng plates lr therelrl and containing the are of the usual 1ead contalnlng typo Hencel 45 usual sulphuric acid electrolyte whose level varies during the electrolytic action of the cell, oxygen between the levels lndlcatedand hydrogen are given oi from the plates and In accordance With this form 0f the Present bubbles of potentially explosive gas will rise invention, there is provided a top or cover asthrough the electrolyte and through the perforasembiy i8 Which is adapted to replace the contiorls 'i into the cellular spaces or nterstices 60 ventional tob 01' Cover 0f the ceii- The top strucd formed by the filler 3 and will then pass to the ture i8 is similar to that above described and atmosphere through the vent tube Il. The eleccomprises e lower plate I9 and an upper plate trolyte level is always maintained above the lower 20 between Which there is disposed the miing section 5 so that no undivided ges chamber of material 2L In this instance. however, the top any appreciable volume is present within the structure, instead 0f being tted dOWn into the cell asv in conventional constructions. Instead, cell s0 as t0 extend belOW the level 0f the electhe ges chamber is in reality a :naze of smelilntrolyte, is Seated upon the upper edges of the tei-connected ges pockets donned by the filler mecontainer'l, as clearly illustrated. This is necesteria1 i3, and the common openings or passages sitated by the plate strap construction employed between pckets will have relatii'ely small areas. o0 in cOnVentiOnal battery Cells Which Willnot Der- In the event that a spark occurs inthe neighbormit thc top Structure to extend below the level hood of the vent tube, the hydrogen and oxygen of the electrolyte. Consequently, there is a space present therein will be ignited, but the quantity l 22 between the electrolyte and the lower cover l of gases and the intensity of the resulting exploplate I9. and the eases in this space may explode. sion will not be suicient to cause any noticeable o5 but it hes been found that the COVel Structure eieot on the oeil, However, the gases Within the reduces the shock of any/ such explosion to' such successive, interconnected gas pockets in the gas an extent that the explosion is inconsequential. chamber will be individually ignited end the com- It will be understood that if the cell construci bustion of the gases will occur consecutively as tion permits, the plate I9 may be recessed into the explosions spread, and a relatively slow series the ceilz 'A of small explosions in this gas mixture will occur The lower cover plate I9 is provided with aperthroughout the gas chamber as the disturbance. tures as before, and permits the ready passage spreads from its point of origin. Thus, the of gases upward into the numerous smalle-interbreaking up of the gas chamber by the material vconnected gas pockets, spaces or interstices I3 does not permit an instantaneous burning of 75 formed by the illlng material 2| If the Upper 

